Predictive Modelling for Incremental Cold Flow Forming: An integrated framework for fundamental understanding and process optimisation

增量冷流成型的预测建模：用于基本理解和流程优化的集成框架

• 批准号: EP/T008415/1
• 负责人: Chris Pearce
• 金额: $ 157.15万
• 依托单位: University of Glasgow
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2020
• 资助国家: 英国
• 起止时间: 2020 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FT008415%2F1
• 关键词: Predictive; Modelling; Incremental; Cold; Flow

Incremental cold flow forming (ICFF) is a metal forming process for the production of high-quality, rotationally-symmetric, hollow engineering components as widely utilised by the aerospace, automotive and oil & gas sectors. In ICFF, a cylindrical preform is attached to a rotating mandrel and axially-translating rollers apply compression to the outer surface. This leads to extrusion of the workpiece material via significant plastic deformation. As a result of the incremental process - rollers are in contact with a small area of the exterior surface of the workpiece at any one time - the extrusion of the material occurs with significantly lower force than required for conventional forming processes. ICFF is thus well suited to high-strength, hard-to-deform materials. The process is "cold" as a coolant is applied where contact occurs between the workpiece and the roller. The deformation occurs significantly below the material's recrystallisation temperature. As a result, cold work hardening occurs leading to increased strength, stiffness and hardness of the final product. A significant advantage of ICFF over conventional forging and deep drawing is the flexibility it gives engineers to design complex components of varying size. ICFF can result in considerable cost savings via improved yields, reduced production times and improved material properties, as compared to standard manufacturing routes. Furthermore, ICFF allows for rapid prototyping to support virtual product design, thereby reducing development cost and driving innovation.Despite the significant advantages that ICFF has over conventional methods, considerable challenges remain. These must be overcome prior to its widespread adoption. Foremost is the unsatisfactory repeatability and reliability of the process; it can be unstable and failure of the material can occur. Controlling the complex ICFF process is challenging. This is compounded by the large number of process parameters and the highly nonlinear nature of the deformation. Critically, there is currently no accurate and robust model to elucidate the fundamental physical mechanisms that occur during ICFF. Without such a model, the application of ICFF to new products and materials will require costly trial-and-error component-scale testing and remain an art as opposed to a science. The primary aim of this collaborative research proposal between the Advanced Forming Research Centre (AFRC) and the Glasgow Computational Engineering Centre (GCEC) is to develop an engineering design framework to model ICFF. Understanding the response of materials to the loading regime imposed by ICFF is a key component of the model development. To this end, we will undertake a detailed materials characterisation study at the AFRC. The loading on the workpiece will be measured using a highly-instrumented, research-dedicated ICFF machine. In addition, a materials characterisation procedure for ICFF will be developed that will allow industry to test new materials for ICFF thereby reducing the need for costly ICFF trials.The computational model will build upon and significantly extend the existing framework provided by MoFEM - a state-of-the-art, general purpose finite element library developed within the GCEC. The model will account for all key features of ICFF, including significant deformations, contact between rotating parts, thermal effects and residual stresses. The highly non-linear and coupled nature of these processes makes modelling challenging. The modular nature of MoFEM allows us to focus on designing new, efficient and robust numerical methods for ICFF rather than developing the core of the library. The ability of the model to accurately simulate a range of ICFF applications will be demonstrated using component scale testing conducted at the AFRC. Finally the predictive capabilities of the model will be assessed by numerically optimising the process parameters to achieve a desired net shape.

增量冷流成形(ICFF)是一种金属成形工艺，用于生产高质量、旋转对称的中空工程部件，广泛应用于航空航天、汽车和石油天然气行业。在ICFF中，圆柱形预制件连接在旋转的芯棒上，轴向平移的滚子对外表面施加压缩。这导致通过显著的塑性变形挤压工件材料。作为增量式工艺的结果--轧辊在任何时候都与工件外表面的一小块区域接触--材料的挤压所需的力明显低于传统成形工艺所需的力。因此，ICFF非常适用于高强度、不易变形的材料。这一过程是“冷的”，因为在工件和轧辊之间发生接触的地方应用了冷却液。变形发生在材料的再结晶温度以下。因此，冷加工硬化会导致最终产品的强度、硬度和硬度增加。与传统锻造和拉深相比，ICFF的一个显著优势是它使工程师能够灵活地设计各种尺寸的复杂部件。与标准制造路线相比，ICFF可以通过提高产量、缩短生产时间和改善材料性能来节省大量成本。此外，ICFF允许快速成型以支持虚拟产品设计，从而降低开发成本并推动创新。尽管ICFF具有传统方法无法比拟的显著优势，但仍然存在相当大的挑战。在广泛采用它之前，必须克服这些问题。最重要的是工艺的重复性和可靠性不能令人满意；它可能不稳定，并可能发生材料故障。控制复杂的ICFF过程是具有挑战性的。大量的工艺参数和高度非线性的变形特性使这一点更加复杂。关键的是，目前还没有准确和可靠的模型来阐明国际气候变化框架会议期间发生的基本物理机制。如果没有这样的模型，ICFF在新产品和材料上的应用将需要昂贵的试错组件规模测试，并且仍然是一门艺术，而不是一门科学。先进成形研究中心(AFRC)和格拉斯哥计算工程中心(GCEC)的这项合作研究提案的主要目的是开发一个工程设计框架来模拟ICFF。了解材料对ICFF施加的加载制度的响应是模型开发的关键组成部分。为此，我们将在AFRC进行详细的材料特性研究。工件上的载荷将使用高度仪表化的研究专用ICF机进行测量。此外，还将开发ICFF的材料表征程序，允许行业测试ICFF的新材料，从而减少昂贵的ICFF试验的需要。计算模型将建立在并显著扩展由GCEC开发的最先进的通用有限元库MofeM提供的现有框架。该模型将考虑ICFF的所有关键特征，包括显著变形、旋转部件之间的接触、热效应和残余应力。这些过程的高度非线性和耦合特性使得建模具有挑战性。MoFE的模块化性质使我们能够专注于为ICFF设计新的、高效的和健壮的数值方法，而不是开发库的核心。该模型能够准确地模拟一系列ICFF应用，将通过AFRC进行的组件规模测试来演示。最后，将通过数值优化工艺参数来评估模型的预测能力，以获得所需的净形状。

项目成果

Multifield finite strain plasticity: Theory and numerics

多场有限应变塑性：理论和数值

• DOI: 10.1016/j.cma.2023.116101
• 发表时间: 2023
• 期刊: Computer Methods in Applied Mechanics and Engineering
• 影响因子: 7.2
• 作者: Lewandowski K

The role of shear dynamics in biofilm formation.

剪切动力学在生物膜形成中的作用。

• DOI: 10.1038/s41522-022-00300-4
• 发表时间: 2022-04-29
• 期刊: NPJ BIOFILMS AND MICROBIOMES
• 影响因子: 9.2
• 作者: Tsagkari, Erifyli;Connelly, Stephanie;Liu, Zhaowei;McBride, Andrew;Sloan, William T.
• 通讯作者: Sloan, William T.